A Hybrid Mattress

ABSTRACT

A mattress has an upper foam panel and a lower foam panel. The panels are molded out of a foam material with integrally preferably molded side walls, and there is an assembly of a plurality of spring units placed and secured on or within the lower foam panel. The upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress.

FIELD OF INVENTION

The present invention generally relates to a mattress for providing comfort to the user. More particularly, the present invention relates to a hybrid mattress with a plurality of coiled springs enclosed between foams.

BACKGROUND OF INVENTION

Various attempts have been made in providing comfortable hybrid mattresses for users which also impart healthcare benefits. Further, a number of specific materials have also been used in manufacturing mattresses in order to provide comfort, such as wool, spring mattresses, sole fabric materials, natural and synthetic latex foam, polyurethane (PU) foam, or other synthetic materials, with or without supports or components such as springs, or air pockets and the like.

Generally, the attempts made to manufacture comfortable mattresses are complex and labor intensive such as, manufacturing a sole piece of latex foam with springs either glued to the surface of the foam or stuck with a holding material. These methods incur more time and labor in making, which eventually increases the manufacturing cost of the mattresses. Additionally, glue provides an undesired stiffness to the mattress and can reduce the mattress life, as the adhesiveness of the glue tends to fade away with time. Furthermore, there are present methods to manufacture hybrid mattresses which involve enclosing springs between the two upper and lower panels of the foam material, and then finally closing the edges with gluing side panels to prepare a final mattress. In such cases, the side panels glued or attached otherwise impart a rough uncomfortable touch feeling to a user/sleeper. In addition to this, the process of additionally attaching the side panels increases the time and cost and is labor intensive.

Most of the present methods and products include mattresses which have pocket springs encased inside the mold of the foam, where the individual springs are surrounded by a fabric. In such products, the springs are mechanically connected with the foam material, for example, with the help of seaming, clips, metallic spirals, metallic stitches, etc. Also, there exist other methods where the springs are maintained inside the foam by surrounding them with foam and/or fabric. Such methods may be expensive and time taking owing to the complexity of the process.

As is clear from the above, present technologies fail to produce mattresses with simpler manufacturing process, which is not complex and expensive. Hence, there arises a need to provide a mattress which is simpler in manufacturing and provides equal comfort to a user. The present invention meets the above.

SUMMARY OF INVENTION

Therefore, it is an objective of the present invention to provide a hybrid mattress which is simple and easy to manufacture and hence less expensive.

It is also an objective of the present invention to provide a hybrid mattress which is equally comfortable on the sides, and do not have a rough and rigid uncomfortable touch feeling to a user.

It is further an objective of the present invention to provide a method of manufacturing a mattress, such that the mattress is composed of two separate halves of a foam material, each half being molded as a single continuous piece of foam material along with edges.

It is an objective of the present invention to not compromise with the comfort and healthcare benefits in order to provide a simple manufacturing process and the device thereof for reducing the cost.

An aspect of the present invention provides a mattress comprising foam panels, an upper foam panel and a lower foam panel, with integrally side walls; preferably integrally molded side walls and an assembly of a plurality of spring units placed and secured within or on the surface of the lower foam panel; wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and wherein the side walls of the upper and the lower foam panels collectively form edges of the of the mattress.

In accordance with a specific embodiment, the present invention provides a mattress comprising two foam panels, an upper foam panel and a lower foam panel, both produced out of a foam material in a continuous quadrilateral shape with integrally produced side walls; and an assembly of a plurality of spring units placed and secured on surface of the lower foam panel; wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly, forms a box-type structure of the mattress; and wherein the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress when secured together, and provide a tight packed arrangement to the assembly of the plurality of spring units inside the mattress.

Another aspect of the present invention provides a method of manufacturing a mattress, comprising two foam panels, preferably molded foam panels, an upper foam panel and a lower foam panel with integrally, preferably molded, side walls; placing and securing an assembly of a plurality of spring units within or on the surface of the lower foam panel; and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units wherein the side walls of the upper and the lower foam panels collectively form edges of the mattress when secured together.

Another specific aspect of the present invention provides a method of manufacturing a mattress, comprising molding two foam panels, preferably two identical, either in shape and/or size and/or material, foam panels, an upper foam panel and a lower foam panel, both molded out of a foam material from a mold, in a continuous quadrilateral shape with integrally molded side walls; placing and securing an assembly of a plurality of spring units on surface of the lower foam panel; and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units and form a box-type structure of the mattress; wherein the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress when secured together, and provide a tight packed arrangement to the assembly of plurality of spring units inside the foam panels.

Another aspect of the present invention provides the method of manufacturing including placing each spring unit on the surface of the lower foam panel, such that each spring unit is supported, in their respective position, by the adjacent ones and also supported and tightly packed by the side walls.

The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of exemplary embodiments of the invention.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 illustrates a perspective view of a mattress showing two molded panels of a foam material, in accordance with an embodiment of the present invention;

FIG. 2 illustrates a perspective view of a lower molded cover panel of the mattress, in accordance with an embodiment of the present invention;

FIG. 3 illustrates a perspective view of the lower molded panel with an assembly of springs tightly packed into it, in accordance with an embodiment of the present invention;

FIG. 4 illustrates an open view of the mattress showing an upper molded panel folded to expose the packed assembly of springs, in accordance with an embodiment of the present invention; and

FIG. 5 illustrates a flow chart showing a method of manufacturing the mattress with two molded foam panels, in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

This patent describes the subject matter for patenting with specificity to meet statutory requirements. However, the description itself is not intended to limit the scope of this patent. The principles described herein may be embodied in many different forms.

Illustrative embodiments of the invention now will be described in more detail hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, the invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

The present invention is directed to a mattress comprising an upper foam panel and a lower foam panel, said panels having integrally produced side walls; and an assembly of a plurality of spring units placed and secured on or within the lower foam panel; wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly, forms the mattress. By integrally produced or integrally molded is meant that the side walls of the foam panel do form part of the foam panel as a single continuous structure. Produced also includes cutting the foam panel out of a foam block. Examples of cutting processes are disclosed in U.S. Pat. Nos. 5,992,633, 3,757,617 and 8,397,387. Preferred producing is the process of molding. Molding processes include those as described in U.S. Pat. Nos. 5,397,225, 2,643,233, 2,809,172, 5,804,113, 9,085,125 and EP1878553.

According to one embodiment the present invention is directed to a mattress comprising an upper foam panel and a lower foam panel, said panels molded out of a foam material with integrally molded side walls; and an assembly of a plurality of spring units placed and secured on or within the lower foam panel; wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly, forms the mattress.

According to a second embodiment the present invention is directed to a mattress comprising an upper foam panel and a lower foam panel, said panels produced out of a foam material in a continuous quadrilateral shape with integrally produced side walls; and an assembly of a plurality of spring units placed and secured on surface of the lower foam panel; wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly, forms a box-type structure of the mattress; and characterized in that the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress, and provide a tight packed arrangement to the assembly of plurality of spring units when the upper foam panel is secured over the lower foam panel.

In the mattress in accordance with the present invention, the upper and lower foam panels can be identical either in shape and/or size and/or material.

Preferably the upper and lower foam panels are produced from a number of foam materials such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams.

Preferably the foam panels are molded into a continuous rectangular, square or any other suitable quadrilateral/geometrical shape.

The mattress in accordance with the present invention comprise a spring unit wherein each spring unit further comprises a coiled spring enclosed in a fabric cover and behaves independently of each other to provide resilience to the mattress.

The coiled spring may be helical or conical in shape and the spring units can be pocket springs.

Typically the spring units are secured to the surface of the lower foam panel using a glue; or metallic stitches; or clips; or any other securing mechanism.

The upper foam panel and the lower foam panel are attached with each other, via a number of methods including and not limited to using a glue, metallic stitches, clips, or any other mechanical connections.

In accordance with a further embodiment of the present invention a method of manufacturing a mattress is provided, comprising producing an upper foam panel and a lower foam panel with integrally produced side walls; placing and securing an assembly of a plurality of spring units within the surface of the lower foam panel; and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units.

A method of manufacturing a mattress is further provided, comprising producing two identical foam panels, an upper foam panel and a lower foam panel, both produced out of a foam material from a mold, in a continuous quadrilateral shape with integrally produced side walls; placing and securing an assembly of a plurality of spring units on surface of the lower foam panel; and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units and form a box-type structure of the mattress; characterized in that the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress, and provide a tight packed arrangement to the assembly of the plurality of spring units, when the upper foam panel is secured over the lower foam panel.

The method as described above further comprises placing each spring unit within the surface of the lower foam panel, such that each spring unit is supported, in their respective positions, by the adjacent ones and also supported and tightly packed by the side walls.

Preferred method is provided whereby the foam panels may be molded into a rectangular, square or any other suitable quadrilateral/geometrical shape and wherein the foam is selected from a number of foam materials such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams, the foam panels being identical in either shape and/or size and/or material. Said foam panels optionally independently comprising perforations and/or profiles.

The present invention discloses a spring mattress for providing tailored comfort to a user/human. The spring mattress, as provided in the preferred embodiment of the present invention, is a combination of a spring assembly incorporated within two molded foams. The mattress comprises two half panels of molded foams, an upper molded panel and a lower molded panel, that are attached together to form one single mattress. Within the two half molded panels, an assembly of a plurality of springs are tightly packed to provide resilience to the mattress. Further, both the half panels of foam are separately molded as one single continuous structure, along with the edges. The molded edges may be referred to as ‘side foam walls’. Therefore, each of the upper and lower molded panel, when joined together form a closed cuboid (box)-type structure, with the side foam walls covering the edges. Hence, the mattress does not need additional separate side panels to seal the mattress from the edges. Hereinafter, the upper and lower molded panels may also be exchangeably referred to as ‘upper and lower cover panel’ or ‘upper and lower foam panel’ or ‘upper and lower molded foam’ or simply ‘upper and lower panel’ without deviating from the meaning and scope of the present invention.

The upper and lower panels may be molded from a number of materials, such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams such as disclosed in U.S. Pat. No. 9,085,125 (assigned to Latexco) and functionalized foams such as disclosed in EP2613927 (assigned to Latexco). Preferably, the upper and lower panels are molded from latex foam.

Further, the mattress also comprises an assembly of a plurality of springs tightly enclosed and packed within the upper and lower foam panels. In an embodiment, each of the spring in the assembly is packed in a fabric case, such that each spring is separated from the other and works independently to provide elasticity to the mattress. Owing to the molded structure of the mattress with the continuous molded side foam walls, the springs can be easily placed within the lower foam panel, where the springs get tightly packed and hence, are restricted to fall or move out of the lower foam panel. Therefore, placing and packing individual spring unit inside the lower foam panel becomes easy and simpler without adopting complex methods of connecting springs with the foam panels to avoid movement of the springs.

In an embodiment, the springs are coiled pocket springs. In another embodiment, the springs may be helical or conical in nature, depending on the requirements of the mattress, without deviating from the meaning and scope of the present invention.

FIG. 1 illustrates a perspective view of the mattress 100 showing two molded foam panels 102 and 104, in accordance with an embodiment of the present invention. As described above, the mattress 100 comprises of two half foam panels, the upper foam panel 102 and the lower foam panel 104, which when joined together form a box-type structure, shown as the mattress 100. This is because both the half foam panels 102 and 104 are individually molded as one single continuous structure along with the side walls. Therefore, the side walls are the integral molded part of the foam panels 102 and 104. The upper and the lower foam panels 102 and 104 behave as an upper and lower cover, making a box-type mattress 100 with a space enclosed in it by the upper foam panel 102, the lower foam panel 104 and the side edges 106 of the resulting box-type mattress 100. Hence, the mattress 100 does not need separate side panels to close it from the edges.

FIG. 2 illustrates a perspective view of the lower foam panel 104 of the mattress 100, in accordance with an embodiment of the present invention. The lower foam panel 104 acts as a lower half of the mattress 100, and is molded out of a foam material, such as latex. The lower foam panel 104 is molded as single continuous structure along with the side walls 200 molded as integral part of the foam panel 104. Similarly, the upper foam panel 102 is molded along with the similar side walls 200.

FIG. 3 illustrates a perspective view of the lower foam panel 104 with an assembly of springs tightly packed into it, in accordance with an embodiment of the present invention. As shown in the FIG. 3, the assembly of springs 300 is tightly packed inside the lower foam panel 104. The assembly of springs comprises a plurality of spring units 302, where each spring is enclosed inside a fabric cover. Hence, each spring unit 302 acts independently of each other in providing elasticity to the mattress 100.

Each spring unit 302 is placed inside the lower foam panel 104 one by one, in such a way that the spring units 302 are supported by the side foam walls 200 of the upper and the lower foam panel 102 and 104. The side walls 200 restrict the movement of the spring units 302, and provide a tightly packed arrangement of the spring units 302 inside the mattress 100.

In the process of putting spring units 302, each spring unit 302 may be simply placed inside the lower panel 104. When each spring unit 302 is placed inside the lower panel 104, they are secured and supported, in their respective positions, by each other and together as an assembly by the side walls 200 (or edges 106 of the mattress). In an embodiment, the spring units may additionally be secured using glue on the surface of the lower foam panel 104. In another embodiment, the spring units may additionally be secured using metallic stitches for connecting them with the surface of the lower foam panel 104. It may be apparent to a person skilled in the art, that there are other mechanisms provided in the art to secure the spring units 302 on the lower foam panel, which can also be adopted in the present invention, without deviating from the meaning and scope of the present invention.

FIG. 4 illustrates an open view 400 of the mattress 100 showing the upper foam panel 102 folded to expose the packed assembly of the spring units 302, in accordance with an embodiment of the present invention. Once all the spring units 302 are secured firmly on the surface of the lower foam panel 104, the upper foam panel 104 is placed above the lower foam panel 104 to cover the spring units 302 and form the full spring mattress 100. The side foam walls of the upper foam panel 102 also provide additional support and restriction to the assembly of the spring units 300. In an embodiment, the upper foam panel 102 may be glued to the lower foam panel to close the mattress 100. In another embodiment, the upper foam panel 102 may be attached to the lower foam panel using metallic stitches, or any other mechanism, such as clips etc. to close the mattress 100. It may be apparent to a person skilled in the art that the present invention may adopt a number of other mechanisms to attach the upper and the lower foam panels with each other, without deviating from the meaning and scope of the present invention.

FIG. 5 illustrates a flow chart showing a method of manufacturing the mattress 100 shown in the FIGS. 1-4. As described by the method 500, at step 502 an upper foam panel 102 and a lower foam panel 104 are molded out from a mold, both with integral side foam walls 200. The upper and the lower foam panels 102 and 104 are continuous one molded piece of a foam material, such as latex foam, with side walls. Further, at step 504, an assembly 300 of a plurality of spring units 302 is secured and tightly packed on the surface of the lower foam panel 104, where the assembly of the spring units 302 is supported by the side walls 200 of the lower foam panel 104. In securing the assembly of the spring units on the lower foam panel 104, each spring unit 302 is placed on the surface of the lower foam panel 104. Eventually, each spring unit 302 supports each other, and is also supported and packed by the side walls 200.

Thereafter, at step 506, once all the spring units 302 are placed on the lower foam panel 104, the upper foam panel 102 is placed and secured over the lower foam panel 104; resultantly forming a mattress 100 into which the assembly of a plurality of spring units 302 is tightly packed due to the presence of molded edges 106 of the mattress 100, which are formed by the side walls 200 of the upper and the lower foam panels 102 and 104.

Advantageously, the present invention provides a mattress and method of manufacturing thereof, where the mattress is a simple combination of two molded foam panels and an assembly of spring units packed inside the two molded foam panels. The two panels are molded as continuous structures along with side walls integral to them. Hence, the mattress does not need extra separate side panels glued to it for covering the edges. Also, since no additional side walls are glued to the upper and lower foam panels, no rough uncomfortable touch feeling is felt by the user.

Further, the assembly of spring units is able to be tightly packed inside the mattress, secured and supported by the upper, the lower and the side walls of the mattress. The spring units may not be necessarily glued to the surface of the lower foam panel, since they are supported by the side walls. Therefore, the mattress is inexpensive and the manufacturing process is not complex and not labor intensive.

Preferred latex foam for the upper and/or lower foam panel is a latex foam. “Latex” is herein defined as a dispersion of polymeric particles in a continuous phase, the polymeric particles preferably having a size range of from 10 to 1000 nm. The latex foam material can be prepared from natural rubber latex or from one or more of such synthetic latexes as polybutadiene/styrene latex, polybutadiene/acrylonitrile latex, polychloroprene latex and the like or from a mixture of natural rubber latex and one or more such synthetic latexes. The later foam includes conventional latex foam as well as visco-elastic latex foam. The solids content of suitable aqueous latexes is from 20 to 75% by weight. Preferred latexes have a solid content of from 50 to 75% by weight. Suitable polymer latexes are all dispersions in which the solid is dispersed in a liquid phase and this phase in turn forms an emulsion with a further liquid phase. Examples are latexes of polymers consisting of dienes or olefinically unsaturated monomers and copolymers thereof, such as polystyrene-butadiene latex, polybutadiene latex, polyisoprene latex, natural rubber latex, acrylonitrile-butadiene latex, polychloroprene latex, polydichlorbutadiene latex, latex of a copolymer of chloroprene and dichlorobutadiene, polyisoprene latex, latex of chlorinated polyisoprene or (meth)acrylate latex. Dispersions of polyurethanes or other dispersions in which polymers are dispersed in water with the aid of emulsifiers or dispersing agents are also suitable, however.

Preferred latexes include latexes of natural rubber, styrene-butadiene rubber (SBR), SBR having low styrene content (up to 27%), nitrile rubber (NBR), isoprene rubber, neoprene rubber, polybutadiene rubber, isobutylene-isoprene rubber (IIR), copolymers of acrylonitrile, methacrylonitrile, acrylates, methacrylates, vinylpyridine with butadiene or 2-chloro-1,3-butadiene and chlorinated polyethylene or mixtures of any of these. Highly preferred are latexes of natural rubber, styrene-butadiene rubber, nitrile rubber, polybutadiene rubber, isoprene rubber or copolymers comprising acrylates. Polymer-containing latexes, such as e.g. SBR (styrene-butadiene rubber) or NBR (acrylonitrile-butadiene rubber), polychloroprene, polybutadiene, polyisoprene, natural rubber latex, polyvinyl chloride, (meth)acrylate dispersions or dispersions of copolymers thereof, are conventionally available commercially in solids concentrations of more than 50%. These concentrations can be achieved e.g. by increasing the concentration of low-concentration polymer latexes. The concentration of natural rubber latex is increased from 30% to 60% solids, for example. Other preferred latexes are combinations of synthetic and natural latex. Preferred proportions of natural latex to synthetic latex can be varied from 1:4 to 6:4. Highly preferred proportions of natural to synthetic latex are more than 1:1. The proportions should be optimized according to the latex used.

Methods of obtaining latex foam are known in the art and can be those where latex being poured into a closed mold provided with aluminium pins to ensure good heat conduction, and subsequently being vulcanised, washed and dried into an end product. An alternative preferred method in accordance with the present invention for producing the latex foam upper and lower foam panel is the pouring of latex foam on an endless conveyor belt, followed by vulcanisation, washing and finally drying.

Other foams to be used are foams selected from polyolefin, polyurethane, polystyrene or polyester or visco-elastic latex or mixtures thereof. The foam can be visco-elastic foam.

The foam offers a firm yet resilient support. Preferred foams to be used in accordance with the present invention are those having a lower indentation load deflection value than the latex foam.

The foam can comprise any natural or synthetic foam. The foams are typically open cell. The foam may also comprise recycled foam, foam impregnated fiber mats or micro-cellular elastomer foam. Additionally, the foam may include organic and/or inorganic fillers. Furthermore, additional additives may be incorporated into the foam composition, such as, but not limited to, flame retardants, anti-fogging agents, ultraviolet absorbers, thermal stabilizers, pigments, colorants, odor control agents, perfumes and the like.

Other preferred foams are polyurethane foam. Polyurethane foams with varying density and hardness may be formed. Tensile strength, tear strength, compression set, air permeability, fatigue resistance, support factor, and cell size distribution may also be varied, as can many other properties. Specific foam characteristics depend upon the selection of the starting materials, the foaming process and conditions, and sometimes on the subsequent processing.

Cellular polyurethane structures typically are prepared by generating a gas during polymerization of a liquid reaction mixture comprised of polyester or polyether polyol, an isocyanate, a surfactant, catalyst and one or more blowing agents. The gas causes foaming of the reaction mixture to form the cellular structure. The surfactant stabilizes the structure.

Latex foam inherently provides a greater independent support characteristic relative to foams such as polyurethane or urethane foams. This difference is attributable to the compositional differences between the materials and is reflected, at least in part, in the typical load deflection curves for each type of material. A load-deflection curve is typically a graph of the force in lbs. required to indent a flat disk of 50 sq. in. (8″ diameter) into the foam or other material being tested for any given percentage of deflection. Latex foam is typically characterized by having a more gradual slope in the lower portion of the curve, that is in the range of 5-10% deflection, which typically becomes steeper in the higher portion of the curve, that in the range of 50-70% of deflection. Polyurethane foams, on the other hand, typically have a steeper initial portion of the curve, in the range of 5-10% deflection, which typically decreases in the higher deflection ranges.

Thus, while latex foam has a softer initial feel, it resists deflection at heavier loads. This contributes, at least in part to the latex foam offering greater independent support relative to urethane foam.

The present invention also provides additional tailoring of the comfort to the user by combining different foams to be used in either the lower foam panel and/or upper foam panel.

Preferred foam panel according to the present invention contain perforations. Preferably said perforations are formed in the mattress in a pattern of rows of perforations and/or columns of perforations, the spacing between two adjacent rows of perforations and/or columns of perforations. Preferably the interface between the spacing of the perforations are less than 40, more preferably less 20 mm, most preferably ranging between 10 and 15 mm.

Combinations of perforations having different sizes can also be used. Sizes of the perforations are between 0.5 and 2 cm. Preferred hybrid mattress according to the present invention are characterized in that the surface of the foam layer above the array of springs are provided with perforations in at least one zone of the upper surface thereof and with a profile in at least one zone of said upper surface.

In addition, the aforesaid perforations are formed in zones near those parts of a user's body that secrete the most sweat, mainly the neck, the back and the thighs.

Preferred upper and/or lower foam panels according to the present invention contain profiles.

The profiles when combined with the foam panels of the present invention present in specific zones at the upper side of the upper layer of the foam panel enhance the sleeping comfort of the user, because the bedding when formulated with the composite foam of the present invention feels softer in said zones, depending on the shape and the dimensions of said profiles.

A suitable selection of the zones comprising perforations alternating with zones comprising profiles will lead to an upper mattress, which meets each and every requirement of an exacting user as regards sleeping comfort.

According to yet another embodiment of the present invention, there is provided a foam including a convoluted top or convoluted second layer, which enhances user comfort.

In accordance with a further preferred aspect of the foam panel according to the present invention there is provided convoluted foam, which increases comfort or softness. The elongated convoluted foam in case of use for bedding, supports a recumbent human body. The bedding comprises an elongated body including an area formed by generally longitudinally extending ribs arranged in rows. Each rib is separated from any adjacent rib by a channel. Each rib includes a plurality of first peaks having a first height and a plurality of second peaks having a second height, different from the first height. The first and second peaks are alternatively disposed along each rib. Preferred feature of the foam panel according to the present invention that each rib is generally sinusoidal about a longitudinal axis to define sinusoidal channels there between. The first peaks are formed at crests of the sinusoidal ribs. The second peaks are formed at the longitudinal axis of each rib. The ribs are wider in areas proximate the first and second peaks. The first and second peaks are rounded. Another preferred feature of the foam panel according to the present invention is that the first height is greater than the second height. It is a further preferred feature of the present invention that the channels have a first thickness in areas proximate the first peaks and a second thickness in areas proximate the second peaks. The second thickness is greater than the first thickness.

While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the present disclosure. Indeed, the novel methods, devices, and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the methods, devices, and systems described herein may be made without departing from the spirit of the present disclosure. 

1. A mattress comprises an upper foam panel and a lower foam panel, said panels having integrally produced side walls, and an assembly of a plurality of spring units placed and secured on or within the lower foam panel, wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress.
 2. A mattress according to claim 1 having an upper foam panel and a lower foam panel, said panels molded out of a foam material with integrally molded side walls, and an assembly of a plurality of spring units placed and secured on or within the lower foam panel, wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly forms the mattress.
 3. A mattress according to claim 1 having an upper foam panel and a lower foam panel, said panels produced out of a foam material in a continuous quadrilateral shape with integrally produced side walls, and an assembly of a plurality of spring units placed and secured on surface of the lower foam panel, wherein the upper foam panel, when secured above the lower foam panel, covers the assembly of the plurality of spring units and resultantly, forms a box-type structure of the mattress, and wherein the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress, and provide a tight packed arrangement to the assembly of plurality of spring units when the upper foam panel is secured over the lower foam panel.
 4. The mattress in accordance with claim 1, whereby the upper and lower foam panels are identical either in shape and/or size and/or material.
 5. The mattress in accordance with claim 1, wherein the upper and lower foam panels are produced from a number of foam materials such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams.
 6. The mattress in accordance with claim 1, wherein the foam panels are molded into a continuous rectangular, square, or any other suitable quadrilateral/geometrical shape.
 7. The mattress as claimed in claim 1, wherein each spring unit further comprises a coiled spring enclosed in a fabric cover and behaves independently of each other to provide resilience to the mattress.
 8. The mattress as claimed in claim 7, wherein the coiled spring may be helical or conical in shape.
 9. The mattress as claimed in claim 1, wherein the spring units are pocket springs.
 10. The mattress as claimed in claim 1, wherein the spring units are secured to the surface of the lower foam panel using a glue, or metallic stitches, or clips, or any other securing mechanism.
 11. The mattress as claimed in claim 1, wherein the upper foam panel and the lower foam panel are attached with each other, via a number of methods including and not limited to using a glue, metallic stitches, clips, or any other mechanical connections.
 12. A method of manufacturing a mattress, comprising producing an upper foam panel and a lower foam panel with integrally produced side walls, placing and securing an assembly of a plurality of spring units within the surface of the lower foam panel, and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units.
 13. A method of manufacturing a mattress according to claim 12, comprising: producing two identical foam panels, an upper foam panel and a lower foam panel, both produced out of a foam material from a mold, in a continuous quadrilateral shape with integrally produced side walls; placing and securing an assembly of a plurality of spring units on surface of the lower foam panel, and placing and securing the upper foam panel over the lower foam panel to fully cover the assembly of the plurality of spring units and form a box-type structure of the mattress, wherein the side walls of the upper and the lower foam panels collectively form edges of the box-type structure of the mattress, and provide a tight packed arrangement to the assembly of the plurality of spring units, when the upper foam panel is secured over the lower foam panel.
 14. The method as claimed in claim 12 further comprises placing each spring unit within the surface of the lower foam panel, such that each spring unit is supported, in its respective position, by the adjacent ones and also supported and tightly packed by the side walls.
 15. The method as claimed in claim 12, wherein the foam panels may be molded into a rectangular, square or any other suitable quadrilateral/geometrical shape and wherein the foam is selected from a number of foam materials such as including and not limited to natural and synthetic latex foam material, polyurethane foam, and other synthetic foam material manufactured by crude oil, and the like including composite foams, the foam panels being identical in either shape and/or size and/or material. Said foam panels optionally independently comprise perforations and/or profiles. 